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A lost Bugatti rises

1 of 5Since the prototypes had different details in different photographs, a decision had to be made as to which version should be created.

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2 of 5The front fenders were built from narrow strips of magnesium that were welded together and then cut in two longitudinally.

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3 of 5Since all of the pictures were black and white, choosing a color presented another small mystery.

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4 of 5Forming the car's myriad compound curves from magnesium was a journey into the unknown.

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5 of 5Bugatti chassis No. 57104

Photo by Ronan McGrath

Thirteen photographs and one small, signed component blueprint are the only records in existence that document the short life of one of the most beautiful Bugattis ever built. Designed by Jean Bugatti, the son of Ettore Bugatti, the Aerolithe preceded the famous Bugatti Atlantiques now in the Ralph Lauren and Mullin collections. The car was a design exercise that clearly led to the Atlantiques, and it was a superbly executed example of the art deco streamlining that was the pinnacle of exotic automotive design in the late prewar period.

The car was built of magnesium, a difficult, brittle, flammable material that in mass production would be a nonstarter. But magnesium does have one very desirable characteristic—it weighs practically nothing.

It was exhibited at the 1935 London motor show, given to two Bugatti enthusiasts for a brief road test, and returned to the factory. It was never sold and was never seen again. Like Elvis and the Yeti, rumors of its existence have surfaced from time to time, but it was most likely destroyed.

But today, a stunning recreation is only months from completion after a four year effort.

David Grainger has long been fascinated by Bugattis and has handled a number of them in his restoration shop, the Guild of Automotive Restorers Near Toronto, Ontario.

Bugatti built its cars using its own machine tools, and an original Bugatti-stamped vise sits in Grainger's showroom. He is deeply knowledgeable about the Type 57 chassis that Bugatti sports cars were built upon. When approached by an anonymous collector to recreate the Aerolithe, what followed was a long and lively quest to create the most accurate replica possible.

Every existing photograph of the car was computerized and analyzed to determine the precise dimensions of the original car, which differs in almost every dimension from the Atlantique, including having a higher hood and grille and a different roofline. Every shadow was deconstructed. Furthermore, since the prototypes had different details in different photographs, a decision had to be made as to which version should be created.

A key question was which chassis and engine had been used. By a careful review, it was determined that a nonsupercharged Type 57 chassis was the basis of the original car. The build would be made on an original chassis, engine and running gear.

Grainger had chassis No. 57104 available, complete with engine. The only major component missing was a matching front axle, and he was able to source one of those as well. No.57104 is the earliest known genuine chassis and there is extensive documentation available on it. Despite a lot of passionate discussion in Bugatti circles that the original Aerolithe had been supercharged, photos were conclusive. A partial photo also provided information on the interior and the dash, which were simple in typical Bugatti form.

Having determined the course of action in broad terms, there remained a huge challenge in figuring out how Bugatti would have fabricated the body in magnesium. Grainger's shop had plenty of experience with steel and aluminum, but forming the car's myriad compound curves from magnesium was a journey into the unknown.

Magnesium does not easily bend and has what metal workers call a “memory” that causes it to return to its original shape. To make things more difficult, the decision was made to use a compound that would have been available in the period rather than the more flexible metals used in postwar years. It also was necessary for the shop to learn how to weld magnesium to the steel and aluminum used for some components. At each step, the key question was, “How would Bugatti have done it?”

The front fenders were built from narrow strips of magnesium that were welded together and then cut in two longitudinally. They were rejoined using raised seams and rivets, which was a distinguishing characteristic of both the Aerolithe and the Atlantiques.

As of this writing, all of the car's component pieces are complete and the car is undergoing final assembly in the workshop. It is estimated that the magnesium body weighs about as much as it would if it had been made of thin carbon fiber, and it is light enough that it can be lifted by two people. When turned over, the multiple strips welded together to build it are clearly evident.

The car has great beauty and immense presence, even in its unfinished form. Grainger said he expects that it will be finished in four or five months.

Even at the stage, the detective work continues. One photograph appeared to show a groove in the door handles. After a great deal of discussion, “the groove” was determined to be a shadow. Since all of the pictures were black and white, choosing a color presented another small mystery. The answer was revealed in a painting of the car that was presented to Jean Bugatti. The painting led the team to a color photograph of contemporary car in the same shade. The Aerolithe replica will be finished in a shade of light silver green matching the color seen in the photograph and the painting.

Other important cars that have been lost to history are now being recreated by skilled craftsmen. Somewhat recently, Audi commissioned a complete recreation of the prewar Auto Union Silver Arrows race cars, most of which perished in and after World War II. Porsche re-created the original Lohner-Porsche hybrid that was an early highlight of Ferdinand Porsche's life as a pioneering figure in automotive history.

The Aerolithe does the same thing, bringing back a car that is thought to be lost forever, and the automotive world will be richer for its reappearance.

Grainger and his team spent years working on this Aerolithe, meticulously creating something real from the most scant evidence. Their next project is a restoration of a completely original and unique car which was built for its famous designer. But that's another story.

NOTE: An earlier version of this story contained an error. Originally, the car was said to be being built upon Bugatti chassis No. 15074. Reader Chris Ohrstrom correctly pointed out that the car is in fact being built on a Bugatti chassis numbered 57104. The story has been corrected and a photograph of the chassis showing the correct chassis number has been added to the gallery.